Chockfast Red is a high-performance, three-component epoxy grout designed for grouting large industrial machinery and supporting soleplates in a variety of foundation types. It is widely used in applications where precision alignment, high compressive strength, and resistance to chemical and thermal stress are essential. Its unique properties, including negligible shrinkage and high flow characteristics, make it ideal for installations that require long-term reliability and minimal maintenance. This article provides a comprehensive overview of the installation procedures for Chockfast Red, based on technical documentation, manufacturer guidelines, and real-world case studies. The information is intended for engineers, technicians, and contractors involved in the installation of critical equipment such as compressors, turbines, generators, and pumps.
Overview of Chockfast Red and Its Key Features
Chockfast Red is a 100% solids epoxy grout that is engineered for the grouting of large, precision-critical industrial machinery. It is specifically formulated to provide high compressive strength, excellent creep resistance, and a low exotherm profile to prevent grout cracking or baseplate warping. One of the key features of Chockfast Red is its ability to maintain precise alignment of machinery, which is critical in applications where millimeter-level tolerances are required for optimal performance.
In addition to its mechanical properties, Chockfast Red is impervious to oil and resistant to a wide range of chemicals. It also bonds strongly to both metal and concrete surfaces, ensuring long-term structural integrity. The grout can be applied in a variety of thicknesses and is suitable for both indoor and outdoor environments, provided that proper installation conditions are met. Its high flow capability is particularly advantageous in large surface area or low clearance installations, where traditional grouts may be difficult to apply.
Preparation and Foundation Readiness
Prior to grouting, it is essential to prepare the foundation to ensure optimal adhesion and performance of the grout. The first step in the process involves removing laitance from the concrete surface to expose the aggregate. This is typically done using a light-duty, handheld pneumatic chipping gun with a chisel or moil-type tool. The goal is to create a rough, aggressive profile with at least 50% of the surface exposed as broken aggregate. This increases the bonding surface area and helps to prevent delamination or failure of the grout over time.
Anchor bolts must also be prepared in accordance with the manufacturer's specifications. For Chockfast Red, it is recommended that anchor bolts be embedded at least 10 bolt diameters for anchoring and 12 bolt diameters for free stretch. This allows for sufficient movement of the bolt during the curing process and prevents the grout from bonding to the bolt, which could compromise the alignment of the machinery.
Expansion joints are another important consideration, particularly for large grout pours exceeding 7 feet (2.1 meters) in length. These joints help to accommodate dimensional changes due to temperature fluctuations and prevent cracking. The recommended spacing between expansion joints is 4 to 7 feet (1.2 to 2.1 meters), depending on the specific application and environmental conditions.
Mixing and Pouring Procedures
The mixing process for Chockfast Red involves combining the three components—resin, hardener, and aggregate—according to the manufacturer's instructions. It is important to follow the specified mixing ratios and procedures to ensure that the grout achieves the desired properties. The components should be mixed in a clean, well-ventilated area, and all tools and equipment should be free of oil, grease, or other contaminants that could affect the performance of the grout.
Once the grout is mixed, it should be placed as soon as possible to prevent premature thickening or separation of the components. The grout is typically poured in stages, beginning with the anchor bolt pockets and working outward to the edges of the baseplate. This method ensures that the grout fills all voids and provides full support for the machinery. In applications where the grout is applied in multiple layers, the first layer should be limited to a depth of up to 6 feet (1.8 meters), followed by a final leveling pour of 4 inches (10 cm) or less to achieve the final alignment.
Chockfast Red's high flow characteristics allow it to be pumped through hoses using peristaltic or progressive cavity pumps. This method eliminates the need for manual transport of the grout and reduces the risk of spillage or uneven distribution. Pumping also enables the grout to reach difficult-to-access areas, such as large skid packages or elevated structures, where traditional pouring methods may be impractical.
Curing and Post-Installation Considerations
After the grout has been placed, it must be allowed to cure according to the manufacturer's specifications. The curing time and temperature requirements depend on the ambient conditions and the specific application. In general, Chockfast Red exhibits a slow, gentle curing profile, which helps to minimize internal stresses and prevent cracking. The grout should be protected from moisture, dust, and temperature fluctuations during the curing process to ensure proper development of its mechanical properties.
Once the grout has fully cured, the machinery can be commissioned and placed into service. It is important to monitor the equipment for any signs of misalignment, vibration, or wear, as these could indicate issues with the grout installation. Regular inspections and maintenance are recommended to ensure that the grout continues to perform as intended and that the machinery remains aligned and stable over time.
Application in Real-World Industrial Projects
A notable example of Chockfast Red's application in a real-world industrial setting is its use in the installation of an electric motor-driven compressor at a facility in Allegheny County, Pennsylvania. In this project, the grout was used to set the compressor and motor unit, which required precise alignment within extremely tight tolerances. The high compressive strength and creep resistance of Chockfast Red ensured that the machinery remained stable and aligned under the operational stresses of the equipment.
The project also faced challenges related to the variable weather conditions typical of late fall in the Pittsburgh area. To accommodate these conditions, a temporary shelter was constructed to protect the grout from the elements, and the area was pre-conditioned for 48 hours prior to the mixing and placement of the grout. Heat was added to the shelter to maintain the required temperature for successful grouting. This case study highlights the importance of proper preparation and adherence to the manufacturer's guidelines, especially when working in less-than-ideal environmental conditions.
Special Considerations for Chockfast Red Versaflow
Chockfast Red Versaflow is a specialized version of the grout that is designed for large surface area and low clearance applications. Its unique high-flow properties allow it to be pumped and delivered through hoses with minimal effort, making it ideal for installations where traditional grouting methods would be impractical. The grout's flow rate is more than 2.7 times faster than that of competitive products, which significantly reduces placement time and labor costs.
The use of hose transport also enhances safety by reducing the need for manual handling of the grout and minimizing the risk of spills or accidents. Additionally, the high flow capability of Chock to pump and deliver the grout through complex or congested areas, such as skid packages or elevated structures. This makes it particularly useful in large-scale industrial projects where time and efficiency are critical factors.
Conclusion
Chockfast Red is a high-performance epoxy grout that is widely used in the installation of critical industrial machinery. Its ability to maintain precise alignment, resist creep, and provide long-term structural integrity makes it an ideal choice for applications where reliability and durability are paramount. The installation process involves careful preparation of the foundation, precise mixing of the grout components, and controlled pouring to ensure full coverage and support for the machinery.
Real-world applications, such as the installation of an electric motor-driven compressor in Allegheny County, demonstrate the effectiveness of Chockfast Red in challenging environments. Specialized versions like Chockfast Red Versaflow offer additional benefits, including faster flow rates and easier pumping, which can significantly reduce labor and time requirements.
For contractors, engineers, and technicians, following the manufacturer's guidelines and best practices is essential to achieving a successful installation. Proper preparation, adherence to mixing and pouring procedures, and attention to environmental conditions all play a role in ensuring that the grout performs as intended and that the machinery remains aligned and stable over time.